Paper-like product, method and apparatus for production thereof and prepreg formed of said paper-like product

Abstract

A paper-like product composed of staple fibers oriented substantially in a certain specific direction is provided, wherein the orientation degree of the constituent staple fibers, expressed by the following formula: <IMAGE> is at least 50%. A prepreg is formed by impregnating the paper-like product with a matrix resin. Composite prepregs are formed by laminating a plurality of such prepregs or such a prepreg with a prepreg composed of continuous filaments, in a manner such that the orientation directions of fibers in the prepregs intersect one another. The paper-like product is prepared by scattering a liquid dispersion of staple fibers in the horizontal direction by a centrifugal force, and collecting the scattered staple fibers in the form of a web on a collecting surface continuously moving in the vertical direction.

We claim: 
     
       1. A paper-like product composed of (a) staple fibers oriented substantially in a direction orthogonal to the longitudinal direction of the paper-like product and (b) binder fibers which are staple fibers having portions parallel and perpendicular to the oriented staple fibers (a); said staple fibers (a) having an orientation degree, expressed by the following formula: ##EQU4## of at least 50%, and the proportioin of the binder fibers (b) being at least about 1.5% by weight based on the total fibers. 
     
     
       2. A paper-like product as set forth in claim 1, wherein the staple fibers (a) have an orientation degree of at least 60%. 
     
     
       3. A paper-like product as set forth in claim 1, wherein the staple fibers (a) have an orientation degree of at least 80%. 
     
     
       4. A paper-like product as set forth in claim 1, wherein some staple fibers (a) are oriented in a direction perpendicular to said direction orthogonal to the longitudinal direction of the paper-like product. 
     
     
       5. A paper-like product as set forth in claim 1 wherein the recited orientation degree of staple fibers (a) is conferred upon it during its manufacture. 
     
     
       6. A prepreg formed by impregnating a paper-like product composed of (a) staple fibers oriented substantially in a direction orthogonal to the longitudinal direction of the paper-like product and (b) binder fibers which are staple fibers having portions parallel and perpendicular to the oriented staple fibers (a), with a matrix resin; said staple fibers (a) having an orientation degree, expressed by the following formula: ##EQU5## of at least 50%, and the proportion of the binder fibers (b) being at least about 1.5% by weight based on the total fibers. 
     
     
       7. A prepreg as set forth in claim 6, wherein the staple fibers (a) have an orientation degree of at least 60%. 
     
     
       8. A prepreg as set forth in claim 6, wherein the staple fibers (a) have an orientation degree of at least 80%. 
     
     
       9. A prepreg as set forth in claim 6 wherein the recited orientation degree of staple fibers (a) is conferred upon the paper-like product during its manufacture. 
     
     
       10. A composite prepreg formed by laminating a plurality of prepregs formed by impregnating a paper-like product composed of (a) staple fibers oriented substantially in a direction orthogonal to the longitudinal direction of the paper-like product and (b) binder fibers which are staple fibers having portions parallel and perpendicular to the oriented staple fibers (a), with a resin matrix, so that the orientation directions of the staple fibers (a) in the prepregs intersect one another; said staple fibers (a) having an orientation degree, expressed by the following formula: ##EQU6## of at least 50%, and the proportion of the binder fibers (b) being at least about 1.5% by weight based on the total fibers. 
     
     
       11. A composite prepreg as set forth in claim 10, wherein the staple fibers (a) have an orientation degree of at least 60%. 
     
     
       12. A composite prepreg as set forth in claim 10, wherein the staple fibers (a) have an orientation degree of at least 80%. 
     
     
       13. A composite prepreg as set forth in claim 10 wherein the recited orientation degree of staple fibers (a) is conferred upon the paper-like product during its manufacture. 
     
     
       14. A composite prepreg formed by laminating a prepreg formed by impregnating a paper-like product composed of (a) staple fibers oriented in a direction orthogonal to the longitudinal direction of the paper-like product and (b) binder fibers which are staple fibers having portions parallel and perpendicular to the oriented staple fibers (a), with a resin matrix, with a prepreg composed of continuous filaments oriented substantially in a certain specific direction, so that the orientation direction of the staple fibers (a) and the orientation direction of the continuous filaments intersect each other; said staple fibers (a) having an orientation degree, expressed by the following formula: ##EQU7## of at least 50%, and the proportion of the binder fibers (b) being at least about 1.5% by weight based on the total fibers. 
     
     
       15. A composite prepreg as set forth in claim 14, wherein the staple fibers (a) have an orientation degree of at least 60%. 
     
     
       16. A composite prepreg as set forth in claim 14, wherein the staple fibers (a) have an orientation degree of at least 80%. 
     
     
       17. A composite prepreg as set forth in claim 14 wherein the recited orientation degree of staple fibers (a) is conferred upon the paper-like product during its manufacture.